What is Industrial camera? Main types and image processing
An industrial camera is a specialized type of camera designed to operate under extreme conditions, including high temperatures, pressure, and vibrations. These cameras are utilized for monitoring the production cycle, tracking items on conveyor belts, detecting extremely small components, and more. Consequently, their applications are virtually boundless.
Reliability
Cameras for industrial use significantly differ from ordinary everyday cameras by their high grade of reliability. Such devices often have sturdy housing that protects internal mechanisms from humidity, dust, harmful gases, and other environmental factors. Manufacturers of industrial cameras use the most durable materials for their production (metals, sometimes-reinforced plastic).
Due to its reinforced design, such equipment solves problems in non-standard or even harsh conditions. Devices with high protection level operate in the temperature range from -40 to +70°C and even higher. Sometimes exactly industrial cameras are used for temperature control inspection. They also have generally resistance against mechanical shocks and vibration.
That is why industrial cameras have a long life cycle. Such webcams and photo cameras can operate longer than dozens of ordinary ones combined.
Accuracy
The highest resolution camera is industrial one. On average, the best devices can shoot images with a resolution of up to 150 million pixels (150 MegaPixels). However, you can find equipment with even higher parameters, for example, VN-25MX with ultra-high resolution 225MP or VN-200MX with 427MP. They may process images with the most unimaginable formats like 15804×12008 or 23760×18012.
Industrial cameras often doing quality control operations. Such tasks involve a high accuracy of results. Therefore, this equipment has a high resolution and high-quality image processing.
Operating principle
The functions of industrial cameras differ greatly from those of standard cameras. Consequently, their design is also distinct. These devices incorporate enhanced measures for lens mounting, a range of supplementary filters, integration with industrial interfaces, and specialized software. Common components such as a flash, viewfinder, or shutter button are absent from these models. They connect to networks through industrial interfaces.
Operation management is typically conducted via a PC and dedicated software. Control systems relay signals through connected cables, which issue commands for various actions.
Industrial wireless cameras have the capability to receive signals wirelessly, such as through Wi-Fi. Infrared cameras and thermal imagers are utilized for operations in extremely challenging environments (for instance, during metal processing).
As illustrated by the aforementioned features, industrial cameras represent highly sophisticated equipment with a multitude of additional components and enhanced durability. As a result, their cost is considerably higher.
When to use industrial camera? The main applications
How to select industrial camera? The type and design of the device varies depending on the field of activity and tasks. Let’s look at devices for all areas in more detail to understand where specific types are used.
Automation and robotics. Machine vision
Devices are widely used in industrial automation and robotics. Equipment for control systems generally needs a high resolution. It has to transfer data quickly to control systems.
Production applications require a machine vision. The machine vision is the application of computer vision in manufacturing. It allows controlling systems to see a live picture of what is happening in reality.
These industrial machine vision cameras work through the following interfaces:
- GigE Vision,
- USB 3.0,
- CameraLink,
- CoaXPress,
- Сamera Link
- FireWire
- Pixel-Shift
They may perform controlling, diagnostics, monitoring, and many other useful actions.
For complex tasks there are smart cameras. They perform more complicated action algorithms.
Production and manufactures
In conveyor systems, cameras can serve as substitutes for specialized sensors (as previously discussed regarding Baumer edge sensors) and oversee their proper functioning. These devices must possess high precision and rapid signal transmission capabilities. It is essential to avert potential errors and emergencies. To operate effectively in this domain, devices equipped with continuous shooting, 3D scanning, and photo focusing functionalities are necessary.
Linear cameras (featuring Line scan technology) are employed in conveyors that transport materials continuously. They are capable of conducting line-by-line scans across the surface of objects. Such features are vital for the printing and lighting industries. These devices incorporate integrated CMOS sensors for this purpose.
In heavy industrial environments characterized by significant pollution and limited visibility, infrared SWIR cameras and multispectral thermal imagers are utilized.
Programmable FPGA industrial cameras come with integrated image processing capabilities, enabling real-time offline processing, thereby reducing the load on the network and personal computers. Baumer stands out as a leading manufacturer of machine vision video sensors. The company has introduced the VeriSens series specifically for these applications.
Science and medicine
As nanotechnology advances and medicine evolves swiftly, a variety of webcams are frequently utilized in these fields. These devices are designed to handle microscopic objects or particles that are invisible to the naked eye. The technology employs specialized matrices such as sCMOS, CCD, and EMCCD. The primary benefits of these matrices include high quantum efficiency, minimal noise, and an extensive depth of the potential well. These cameras are capable of operating in extremely low light environments and can identify faint signals. Certain models are even capable of capturing individual photons.
Hyperspectral and multispectral cameras are used to work with spectral channels. They are capable of capturing up to several hundred spectral channels in each frame.
The medicine industry requires compact models. For example, microscopic cameras are capable of transmitting images with high expansion, while having a miniature size. Today this equipment works in almost all branches of medicine, from dentistry to laboratories (endoscopes, borescopes, microscopes, etc.).
Special cameras are developed to work in cryogenics. They have unique protection against extremely low temperatures.
Traffic control
If you have recently received a photograph of your traffic infraction, it is important to understand that you have been captured by an industrial camera. To monitor traffic, specialized high-speed cameras are employed to capture fast-moving objects. These cameras can function at a frequency ranging from 1,000 to 1,000,000 frames per second.
The outdoor equipment must be housed in a dustproof and waterproof enclosure. For traffic management purposes, it is essential that the equipment operates continuously and has a long lifespan. This requirement pertains to both the external and internal components of the assembly.
In security systems and everyday life
In the 21st century, cameras are predominantly associated with security. The installation of industrial security cameras necessitates adaptability and compact housing dimensions.
Security systems utilize industrial cameras that can be installed in nearly any location.
The primary requirements for these devices include stability, compactness, and flexibility. Outdoor industrial security cameras must be safeguarded against environmental factors. Models equipped with night vision are often essential, particularly for television use. Additionally, action cameras are extensively utilized by the general public. They have the capability to transmit images in 4k / UHD and 2k / HD resolutions. With these cameras, one can create slow-motion footage regardless of their location.
Low cost industrial camera
If you are in search of an economical industrial camera, open-frame devices present an excellent option. They can be integrated into your current system without incurring extra costs for additional protection. Furthermore, these devices may incorporate computer vision capabilities through the functioning of CMOS and CCD sensors.
The primary drawback of this option is, naturally, its level of protection. It is advisable not to install them in hazardous locations or outdoors! However, with appropriate installation, they can operate effectively in all the aforementioned environments.
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